Conair EP2 Series Original Instructions Manual
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Conair EP2 Series Original Instructions Manual

Portable and remote condenser chillers-ce version
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USER GUIDE
www.conairgroup.com
UGH041-1015-CE
EP2 Series Portable Chillers
Portable and Remote Condenser Chillers-CE Version
Or ig in al Ins tru ction s
Corporate Office: 724.584.5500  Instant Access 24/7 (Parts and Service): 800.458.1960  Parts and Service: 814.437.6861

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  • Page 1 USER GUIDE www.conairgroup.com UGH041-1015-CE EP2 Series Portable Chillers Portable and Remote Condenser Chillers-CE Version Or ig in al Ins tru ction s Corporate Office: 724.584.5500  Instant Access 24/7 (Parts and Service): 800.458.1960  Parts and Service: 814.437.6861...
  • Page 2 Disclaimer: Conair shall not be liable for errors contained in this User Guide or for incidental, consequential damages in connection with the furnishing, performance or use of this information. Conair makes no warranty of any kind with regard to this information, including, but not limited to the implied warranties of merchantability and fitness for a particular purpose.
  • Page 3 EC Declaration of Conformity The Conair Group 200 West Kensinger Drive, Cranberry Township, Pennsylvania 16066 - USA +1 724 585 5500 phone, +1 724 584 5299 fax, www.conairgroup.com website Hereby declare that: Equipment Air Cooled Portable Industrial Chiller Model number...

  • Page 4: Table Of Contents

    Table of Contents Foreword..................................8   Shipping, Operating, and Storage Ranges............................. 8   Temperature Ranges....................................8   Altitude Ranges ......................................2   Humidity Ranges ......................................2   Safety Guidelines ................................. 3   Pre-Installation................................1   Receiving Inspection ....................................... 1   Unit Storage........................................
  • Page 5 Compressor Hours Button ..................................15   Pump Hours Button.......................................16   Pump Test Button......................................16   Display/Program Button....................................16   Up Button ..........................................16   Down Button ........................................16   Control Power On LED....................................16   Autostart Signal LED......................................16   Pump LED ..........................................17   Hot Gas Bypass LED.......................................17  ...
  • Page 6 Alarms Button ......................................27   Process Diagnostic Button ..................................27   Main Button.........................................27   Compressor Setup Screen...................................28   Process Setup Button....................................28   PID Setup ........................................28   FreezeStat Setup Button ..................................28   Main Button.........................................28   Process Setup Screen....................................28   HGBP PID Button .......................................28  ...
  • Page 7 Once a Month........................................36   Every Three Months.......................................36   Preventive Maintenance Checklist........................... 37   Troubleshooting................................. 38   Drawings ..................................39   Waste Disposal ................................39   Refrigerant and Compressor Oil Disposal ............................39   Disposal of Equipment ....................................40  ...

  • Page 8: Foreword

    Foreword The portable chiller is a packaged unit typically consisting of a refrigeration circuit and a coolant reservoir and pumping system in a compact packaged cabinet for easy location in industrial applications where chilled water is required. The intent of this manual is to serve as a guide for placing your portable chiller in service and operating and maintaining it properly.

  • Page 9: Altitude Ranges

    Low Ambient Indoor Units......0°F to 110°F Outdoor-Duty Units........-20°F to 110°F Storage..............32°F to 145°F Altitude Ranges Transportation........-100 to 26,350 feet Operation...........-100 to 3,280 feet Storage............-100 to 9,840 feet Humidity Ranges Transportation.....0% to 95% RH, non-condensing Operation......0% to 95% RH, non-condensing Storage......0% to 95% RH, non-condensing...

  • Page 10: Safety Guidelines

    Safety Guidelines Observe all safety precautions during installation, start-up, and service of this equipment. The following is a list of symbols used in this manual and their meaning. General Mandatory Action General Warning Wear Eye Protection Electricity Warning Wear Protective Gloves Hot Surface Warning Wear Ear Protection Flammable Material Warning...

  • Page 11: Pre-Installation

    Pre-Installation Receiving Inspection When the unit arrives, verify it is the correct unit by comparing the information that appears on the unit nameplate with that which appears on the order acknowledgement and shipping papers. Inspect the equipment condition for any visible damage and verify all items shown on the bill of lading are present. If damage is evident, properly document it on the delivery receipt and clearly mark any item with damage as “unit damage”...

  • Page 12: Installation - Chiller Mechanical

    Installation – Chiller Mechanical Unit Location The chiller is available in many different configurations to allow each unit to meet the environment in which used. Please refer to the proposal and order acknowledgement for this equipment to verify the specific design conditions in which your chiller is to operate.

  • Page 13: Chilled Water Piping

    Chilled Water Piping Proper insulation of chilled water piping is crucial to prevent condensation. The formation of condensation on chiller water piping, the state change of the water from gas to liquid, adds a substantial heat load to the system and becomes an additional burden for the chiller.

  • Page 14: Installation - Remote Air-Cooled Condenser

    condenser. To ensure proper water flow through the condenser, the condenser water pump should be able to provide at least 25 psi. Each condenser has a two-way condenser water-regulating valve. Under varying loads and condenser inlet water temperatures the amount of cooling water needed varies. The condenser water-regulating valve controls the amount of water allowed to pass through the condenser in order to maintain proper refrigeration pressures in the circuit.

  • Page 15: Refrigeration Piping Design

    CAUTION: Use refrigerant grade copper tubing ASTM B280 only and isolate the refrigeration lines from building structures to prevent transfer of vibration. All copper tubing must have a pressure rating suitable for R-410A: tubing that is ¾” OD or larger must be Type K rigid tubing. ACR annealed tubing coil may be used for sizes ⅝”...
  • Page 16 4. To form a proper liquid seal at the condenser, immediately drop at least 15 inches down from the liquid outlet before routing the piping to the chiller. Make the drop leg before any bends or angles connecting to the remainder of the liquid connection piping.

  • Page 17: Determining Equivalent Line Length

    Figure 4 - Condenser Located Below Chiller Unit Chiller 10' MAX CAUTION: Liquid line sizing for each chiller capacity is in Table 6. These line sizes are listed per circuit and apply where leaving water temperature (LWT) is 40°F or higher. For applications where the LWT is below 40°F, size lines using the ASHRAE Refrigeration Handbook or other suitable design guide.

  • Page 18: Liquid Line Sizing

    Table 1 – Equivalent Lengths of Fittings Equivalent Lengths of Refrigerant Pipe (feet) Line Size OD (in) Elbow 90° Elbow 90° Elbow 90° Elbow 45° Elbow 45° Standard Long Radius Street Standard Street ⅞ 1⅛ 1⅜ 1⅝ 2⅛ 2⅝ 10.0 3⅛...
  • Page 19 Table 2 – Liquid Line Sizes for R410A 5 Ton Circuit (R410A) 7½ Ton Circuit (R410A) Liquid Line Size (Inch OD) Liquid Line Size (Inch OD) Total Total Horizont Equivalent Equivalent Upflow Upflow Upflow Horizontal Upflow Upflow Upflow Length Length 1 to 5 6 to 10 11 to 15...
  • Page 20 Table 2 – Liquid Line Sizes for R410A (continued) 20 Ton Circuit (R410A) 25 Ton Circuit (R410A) Liquid Line Size (Inch OD) Liquid Line Size (Inch OD) Total Total Horizont Equivalent Equivalent Upflow Upflow Upflow Horizontal Upflow Upflow Upflow Length Length 1 to 5 6 to 10...

  • Page 21: Discharge (Hot Gas) Line Sizing

    Table 2 – Liquid Line Sizes for R410A (continued) Figure 5 – Vertical Riser Traps 40 Ton Circuit (R410A) VERTICLE UPFLOW DISCHARGE RISER Liquid Line Size (Inch OD) Total Equivalent Horizontal Upflow Upflow Upflow REVERSE Length 1 to 5 6 to 10 11 to 15 TRAP TO ...
  • Page 22 Figure 6 - Double Discharge Riser PITCH TO CONDENSER REDUCING FROM  CHILLER 90 DEGREE 45 DEGREE STREET ELBOWS STREET ELBOWS CAUTION: Discharge line sizing shown in Table 3 and Figure 4 are listed per circuit and applies where leaving water temperature (LWT) is 40°F or higher. For applications where LWT is below 40°F, size lines using the ASHRAE Refrigeration Handbook or other suitable design guide.

  • Page 23: Calculating System Refrigerant And Oil Charge

    Calculating System Refrigerant and Oil Charge To determine the approximate charge, first refer to Table 5 and establish the require charge for the condenser and chiller. Then refer to Table 6 to determine the charge required for the field-installed piping per circuit. The approximate charge per circuit is therefore the sum of the values from Table 5 and Table 6.

  • Page 24: Installation - Electrical

    WARNING: This equipment contains hazardous voltages that can cause severe injury or death. Installation - Electrical WARNING: This equipment contains refrigerant All wiring must comply with local codes and the under pressure. Accidental release of refrigerant National Electric Code (NEC). Minimum Circuit Amps under pressure can cause personal injury and or property damage.

  • Page 25: Standard Controller Operation

    Standard Controller Operation Stop Button Depressing the Stop button will shut off the compressor, pump, condenser fans (if the chiller is air-cooled), and clear all fault signals. If the Autostart feature is enabled and there is an Autostart signal present, the Stop button will not stop the chiller. See the Program Menu section for instructions on how to enable or disable the Autostart feature.

  • Page 26: Pump Hours Button

    Pump Hours Button Up Button Press and hold the Pump Running Hours Button to The Up Arrow button raises the set point display the amount of time that the pump has been temperature. Pressing the Up Arrow and releasing it enabled.

  • Page 27: Pump Led

    CAUTION: Do not introduce any external voltage board has a compressor anti-cycle delay timer built to the Autostart contacts, as this will result in in. Any time that a compressor is being prevented damage to the microprocessor. from turning on by the anti-cycle timer, the Compressor Recycle LED will be lit.

  • Page 28: Freezestat Led

    pump to establish flow. This safety will shut off the Low Refrigerant Pressure LED pump and the compressor. If the chiller has been shut down by the No Flow safety, the Start button If the compressor suction pressure drops below the must be depressed in order to restart the pump and setting on the low refrigerant pressure safety, the reset the 5 second time delay.

  • Page 29: Program Menu

    Program Menu To change an item, press the Display/Program button until the item code displays in the Process The program menu provides access to a number of display. Pressing the Alarm Reset button and control user-adjustable parameters and feature Display/Program button at the same time will enable/disable control.
  • Page 30 Table 8 - Controller Program Menu Item Name Item Code Default Value Range Alarm Delay - High Deviation 10 to 60 Alarm Delay - Low Deviation 10 to 60 Autostart Enabled Disabled (DIS) or Enabled (EnA) Brownout Enabled Disabled (DIS) or Enabled (EnA) Comm Baud Rate 12 to 96 Comm Modbus ID...
  • Page 31 Table 9 – Controller Control Fault Logic Pump Alarm Manual Remote Alarm Compressor Fault Shut Reset Reset Alarm Indication Shut Off Required Required Activated Low Reservoir The Reservoir Level Light flashes red Level Temperature Limit The Set Point and Process Safety Temperatures Flash and the Temperature Limit Light flashes red...

  • Page 32: Spi Communications (Optional)

    Units ordered with this option will have this feature activated at the factory. If for some reason this SPI Communications (Optional) feature is deactivated it may be active using the Several members of SPI: The Plastics Industry Trade program menu Communication Type function. See Association joined together to define a Table 8 for details.

  • Page 33: Modbus Rtu (Optional)

    Table 10 - SPI Parameters (continued) Command Poll Select Description Status, Machine 1 20 42 This is the machine status in a 16 bit format as follows: 0 = Controlling 1 = An alarm is present 2 = An alarm affecting the process has occurred (high temperature deviation or low temperature deviation) 3 = An alarm affecting the machine operation has occurred (probe fault or pump fault)
  • Page 34 Table 11 – ModBUS RTU Option Parameters (Integral Values) - continued Description Read/Write Notes 4011 LOW ALARM DELAY 4012 HI ALARM DELAY 4013 DISPLAY UNITS 0 = Deg F, 1 = Deg C 4014 CONTROLLER TYPE 0 = TCU, 1 = Chiller 4015 BROWNOUT ENABLED 0 = DISABLED, 1 = ENABLED...
  • Page 35 Note: All temperatures are in °C regardless of unit display configuration. Table 12 – ModBus RTU Option Parameters (Floating Point Values) - continued Description Read/Write Notes 8028 NOT USED 8030 ZERO CAL CHAN 0 8032 ZERO CAL CHAN 1 8034 ZERO CAL CHAN 2 8036 ZERO CAL CHAN 3...

  • Page 36: Optional Controller Operation

    Pressing this button will start the chiller if “Local also be reached from the Active Alarms/Alarm Control” is ON. If “Start” is shown the chiller is OFF. If History screen by pressing the “Conair Contact Info” “Running” is shown the chiller is ON. button.

  • Page 37: Active Alarms Screen

    Alarm History Screen This screen displays the most recent alarms. Active Alarms Screen Up and Down Buttons Touching the Up or Down button scrolls through the This screen displays all active alarms and provides available alarms in the alarm history table. the ability to reset alarms and navigate to the Alarm History screen.

  • Page 38: Compressor Setup Screen

    Process Setup Screen The process setup screen displays and allows Compressor Setup Screen adjustment of the temperature alarms. This screen displays and allows adjustment of various compressor control parameters. The Process Setup Screen displays and allows for the adjustment of the high and low temperature The Compressor Setup screen is password protected.

  • Page 39: Hot Gas Bypass Screen Pid Tuning Screen

    Freezestat Setup Screen This screen displays and allows adjustment of the Hot Gas Bypass Screen PID Tuning Freezestat settings. Screen This screen displays and allows adjustment of the PID parameters of the hot gas bypass valve. The Freezestat is a freeze protection safety that shuts down the chiller if the coolant temperature gets to cold.

  • Page 40: Process Diagnostic Screen

    I/O Status Screen This screen shows the digital inputs and outputs Process Diagnostic Screen from the chiller PLC. A “0” represents OFF while “1” This screen displays the operating status of the represents ON. Each symbol (Y0, Y1, etc.) represents coolant temperature, pump status, and the hot gas a physical input or output.

  • Page 41: Refrigeration Diagnostic Screen

    We strongly recommend the following start-up procedure be performed by a qualified experienced refrigeration technician and must be followed in Refrigeration Diagnostic Screen sequence. If trouble is encountered the fault can This screen displays the operating status of the set usually be traced to one of the control or safety point and actual temperatures, hot gas bypass valve devices.

  • Page 42: Step 1 - Connect Main Power

    Sometimes the source of the water can be the cause of some of the problems. Anyone living in an area Step 1 - Connect Main Power with extremely hard water that has caused scale Connect main power properly ensuring it matches build up can attest to that.
  • Page 43 Improperly designed or installed systems may cause filtration, monitoring, treatment and control devices. unsatisfactory operation and/or system failure. With the ever-changing regulations on water usage and treatment chemicals, the information is always The complex nature of water chemistry requires a up to date when a specialist in the industry is involved.

  • Page 44: Step 3 - Check Condenser

    Step 3 - Check Condenser against a possible freeze-up if no glycol has been added to the coolant. Once the proper glycol There are three possible types of condenser present solution has been added, the Freezestat can be in the chiller: Integral air-cooled, water-cooled, and adjusted to the appropriate setting.

  • Page 45: Preventive Maintenance

    compressor may cycle on and off causing swings in these procedures will almost always more than pay temperature. for it. WARNING: Under no circumstance should the WARNING: Authorized personnel only, only High Refrigerant Pressure or the Low Compressor qualified service technicians or operators are to Pressure switch be deactivated.

  • Page 46: Once A Month

    6. Check refrigerant sight glass for air bubbles or moisture indication. If the sight glass indicates that there is a refrigeration problem, have the unit serviced as soon as possible. Once a Month Repeat items 1 through 6 and continue with the following.

  • Page 47: Preventive Maintenance Checklist

    Preventive Maintenance Checklist Week Number Maintenance Activity Date Clean Condenser Coil and Inlet Filter (air cooled units) Temperature Control Pump Discharge Pressure Coolant Level Glycol Concentration Pump Seal Refrigerant Sight Glass Electrical Connections Incoming Voltage Compressor #1 L1 Amps Compressor #1 L2 Amps Compressor #1 L3 Amps Compressor #2 L1 Amps Compressor #2 L2 Amps...

  • Page 48: Troubleshooting

    Troubleshooting Problem Possible Cause Remedy Compressor will not Compressor overload Check supply voltage, amperage of each leg, start contactor and wiring, and overload set point Compressor contactor Replace if faulty Compressor failure Contact Customer Service for assistance Pump will not start Pump overload Check supply voltage, amperage of each leg, contactor and wiring, and overload set point...

  • Page 49: Drawings

    Troubleshooting (continued) Problem Possible Cause Remedy Erratic temperature Low coolant flow through evaporator Adjust flow to proper level control Intermittent overloading of chiller capacity Check to make sure chiller is properly sized for process load Hot gas bypass valve Contact refrigeration service technician Temperature sensor Replace if faulty Insufficient cooling...

  • Page 50: Disposal Of Equipment

    CAUTION: The chiller will exceed 70 dBA sound pressure at 1 meter distance and 1 meter elevation when operating. Wear ear protection as required for personnel comfort when operating or working in close proximity to the chiller. CAUTION: Wear protective gloves when installing, maintaining, or repairing the equipment to protect against any sparks, debris, or fluid leaks.
  • Page 51 We’re Here to Help Conair has made the largest investment in customer support in the plastics industry. Our service experts are available to help with any problem you might have installing and operating your equipment. Your Conair sales representative also can help analyze the nature of your problem, assuring that it did not result from misapplication or improper use.
  • Page 52 (except for parts that are typically replaced after normal usage, such as filters, liner plates, etc.). Conair’s guarantee is limited to replacing, at our option, the part or parts determined by us to be defective after examination. The customer assumes the cost of transportation of the part or parts to and from the factory.

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